2020 Subaru Crosstrek Base, Automatic CVT TransFACTORY OEM SERVICE PROCEDURE

Intake Manifold Assembly: Removal

  1. If the fuel delivery tube is disconnected after removing the intake manifold assembly, perform the following work.
    1. Release the fuel pressure. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (EXCEPT FOR HEV))>FUEL>PROCEDURE>RELEASING OF FUEL PRESSURE .
    2. Open the fuel filler lid and remove the fuel filler cap.
    NOTE: This operation is required to release the inner pressure of the fuel tank.
  2. Remove the battery. Refer to STARTING/CHARGING SYSTEMS (H4DO (EXCEPT FOR HEV))>BATTERY>REMOVAL .
  3. Remove the clip from the air intake boot, and loosen the clamp.
    G11252776Courtesy of SUBARU OF AMERICA, INC.
  4. Remove the air intake boot, and place it aside so that it does not interfere with the work.
    CAUTION: Be careful not to pull out the PCV hose.
    G11252777Courtesy of SUBARU OF AMERICA, INC.
  5. When the engine coolant remains before removing the intake manifold assembly
    1. Disconnect the connector (A).
    2. Remove the bolts securing the throttle body, and move the throttle body aside so that it does not interfere with the work.
    G13600108Courtesy of SUBARU OF AMERICA, INC.
  6. When the engine coolant has been drained before removing the intake manifold assembly
    1. Disconnect the connector (A), and disconnect the preheater hose (B).
    G13600109Courtesy of SUBARU OF AMERICA, INC.
  7. Disconnect the connector (A) from manifold absolute pressure sensor.
  8. Disconnect the connector (B) from the purge control solenoid valve, and remove clip (C).
  9. Disconnect the purge hose (D) from the purge control solenoid valve.
  10. Disconnect the PCV hose No. 1 (E).
  11. Remove the bolt securing the fuel pipe.
    G13600110Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the connector (A) from the tumble generator valve RH.
  13. Remove the fuel delivery tube clamp (B).
  14. Remove clip (C) securing the engine wiring harness.
    G11252784Courtesy of SUBARU OF AMERICA, INC.
  15. Remove nut (A) securing the EGR cooler to the EGR control valve.
  16. Remove stud bolt (B) using TORX® E8.
  17. Loosen bolts (C) securing the EGR cooler to the cylinder head RH.
    G11252785Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the V-belt covers.
    G12391348Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the connector (A), connector (B) and terminal (C). (Fixed capacity A/C model)
  20. Remove the clip (D) and clip (E) that secure the battery cable assembly. (Fixed capacity A/C model)
    G11252787Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the connector (A), connector (B), connector (C) and terminal (D). (Variable capacity A/C model)
  22. Remove the clip (E) and clip (F) securing the battery cable assembly. (Variable capacity A/C model)
    G11252788Courtesy of SUBARU OF AMERICA, INC.
  23. Disconnect the connector (A) from the EGR control valve.
  24. Remove the fuel delivery tube.
    G12391351Courtesy of SUBARU OF AMERICA, INC.
  25. Disconnect the brake booster vacuum hose (A).
  26. Remove clip (B) securing battery cable assembly.
  27. Disengage 2 claws (C) and remove the harness protector.
    G11252790Courtesy of SUBARU OF AMERICA, INC.
  28. Disconnect the connector (A) from the tumble generator valve LH.
  29. Use a pair of nippers to cut off the clip securing the engine wiring harness, and remove the clip from the intake manifold assembly.
    NOTE: Put alignment marks (a) on the clip and the engine wiring harness.
    G13229552Courtesy of SUBARU OF AMERICA, INC.
    G13229553Courtesy of SUBARU OF AMERICA, INC.
  30. Disconnect connector (A) from ECM. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (EXCEPT FOR HEV))>ENGINE CONTROL MODULE (ECM)>REMOVAL .
  31. Disconnect the connector (B) and terminal (C) from the main fuse box, and remove the engine wiring harness from the clip (D).
    G13600120Courtesy of SUBARU OF AMERICA, INC.
  32. Release the claw (A) securing the battery cable assembly to the bracket.
  33. Release the claw (B) securing the engine wiring harness to the bracket, and place it aside so that it does not interfere with work.
    G13223839Courtesy of SUBARU OF AMERICA, INC.
  34. Remove the fuel pipe protector. (Impreza model)
    G12391354Courtesy of SUBARU OF AMERICA, INC.
  35. Remove the fuel pipe protector No. 1. (Crosstrek model)
    G12391355Courtesy of SUBARU OF AMERICA, INC.
  36. Remove the intake manifold assembly.
    • RH side
      G11252792Courtesy of SUBARU OF AMERICA, INC.
    • LH side
      G11252793Courtesy of SUBARU OF AMERICA, INC.
  37. Remove the cylinder head plate from cylinder head.
    NOTE: Perform this procedure only when required.
    G11252794Courtesy of SUBARU OF AMERICA, INC.
  38. Disconnect the fuel delivery pipe from the high-pressure fuel pump. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (EXCEPT FOR HEV))>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE C) .
    G11252795Courtesy of SUBARU OF AMERICA, INC.
  39. Disconnect the fuel delivery pipe (A) from the fuel pipe. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (EXCEPT FOR HEV))>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE B) .
  40. Disconnect the fuel delivery tube (B) from the fuel pipe. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (EXCEPT FOR HEV))>FUEL DELIVERY AND EVAPORATION LINES>REMOVAL>QUICK CONNECTOR DISCONNECTION (TYPE A) .
    G11252796Courtesy of SUBARU OF AMERICA, INC.
  41. When removing fuel pipe protector No. 2 (Crosstrek model)
    1. Remove the camshaft position sensor (intake LH side). Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (EXCEPT FOR HEV))>CAMSHAFT POSITION SENSOR>REMOVAL>INTAKE SIDE .
    2. Remove the fuel pipe protector No. 2.
    G12391361Courtesy of SUBARU OF AMERICA, INC.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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